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Kawasaki FH601D - Service Manual
FH601D, FH641D
FH680D
4–stroke air-cooled v-twin gasoline engine
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of
Quality Assurance Department/Consumer Products & Machinery Group/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such
changes to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model
component parts.
© Kawasaki Heavy Industries, Ltd. 2000
Second Edition (1) : Dec. 11, 2000 (K)
Summary of FH601D -
Page 1
Fh601d, fh641d fh680d 4–stroke air-cooled v-twin gasoline engine service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior...
Page 2
List of abbreviations a ampere(s) lb pound(s) abdc after bottom dead center m meter(s) ac alternating current min minute(s) atdc after top dead center n newton(s) bbdc before bottom dead center pa pascal(s) bdc bottom dead center ps horsepower btdc before top dead center psi pound(s) per square inch...
Page 3
Emission control information to protect the environment in which we all live, kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems (em) in compliance with applicable regulations of the united states environmental protection agency and california air resources boa...
Page 4: Foreword
Foreword this manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper us...
Page 5: General Information
General information 1-1 general information table of contents 1 before servicing.................................................................................................................................................................1-2 model identification .....................................
Page 6
1-2 general information before servicing before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed accoun...
Page 7
General information 1-3 before servicing (15) cotter pin replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (16) lubrication engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricati...
Page 8
1-4 general information model identification cylinder number designation: no.1 cylinder is on the electric starter side. No.2 cylinder is on the oil fileter side..
Page 9
General information 1-5 general specifications items fh601d, fh641d, fh680d type of engine forced air-cooled, horizontal shaft, ohv, 4-stroke gasoline engine. Cylinder layout 90 v-twin bore x stroke 75.2 mm x 76 mm (2.96 in x 2.99 in) piston displacement 675 ml (41.19 cu. In) direction of rotation c...
Page 10
1-6 general information periodic maintenance chart to ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The periodic maintenance chart below shows periodic inspection and maintenance items and suitable intervals. The bullet mark ...
Page 11
General information 1-7 torque and locking agent the following tables lists the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "remarks" column mean: l : apply a non-permanent locking agent to the threads....
Page 12
1-8 general information torque and locking agent fastener torque remarks n 1 m kg 1 m ft 1 lb lubrication system: engine drain plugs (plastic) 6.9 0.7 61 in 1 lb engine drain plug (metal) 20 2.0 14.5 engine drain plug joint (plastic) 17 1.7 12 engine drain plug joint (metal) 39 4.0 29 oil pressure s...
Page 13
General information 1-9 special tools compression gauge: 57001–221 piston ring pliers: 57001–115 piston ring compression grip: 57001–1095 piston ring compression belt, Ø67 -Ø79: 57001–1097 valve seat cutter holder bar: 57001–1128 valve seat cutter holder Ø6: 57001–1360 valve seat cutter, 45 – 35.0 :...
Page 14
1-10 general information special tools oil filter wrench : 57001–1249 hand tester: 57001–1394 kawasaki bond (silicone sealant) : 56019–120
Page 15: Fuel System
Fuel system 2-1 fuel system table of contents 2 exploded view.............................................................2-2 specifications...............................................................2-4 governor link mechanism .......................................... 2-5 control panel assembly...
Page 16
2-2 fuel system exploded view 1. Pilot screw 2. Pilot air jet 3. Main air jet 4. Main jet 5. Pilot jet 6. Solenoid valve t1: 0.95 n 1 m (0.097 kg 1 m, 8.4 in 1 lb) t2: 0.98 n 1 m (0.1 kg 1 m, 8.7 in 1 lb) t3: 2.0 n 1 m (0.2 kg 1 m, 18 in 1 lb) t4: 3.4 n 1 m (0.35 kg 1 m, 30 in 1 lb) t5: 5.9 n 1 m (0...
Page 17
Fuel system 2-3 exploded view o: apply engine oil. T1: 2.0 n 1 m (0.2 kg 1 m, 17 in 1 lb) t2: 5.9 n 1 m (0.6 kg 1 m, 52 in 1 lb) t3: 7.8 n 1 m (0.8 kg 1 m, 69 in 1 lb).
Page 18
2-4 fuel system specifications item standard fh601d, fh641d fh680d caburetors specifications: make/ type nikki 13y244 nikki 621266 throttle bore diameter 24 mm (0.94 in.) 26 mm (1.02 in) venturi diameter 18 mm (0.71 in.) 21 mm (0.83 in) main jet (mj) l: #92, r: #95 #108 (l and r) pilot jet (pj) #54 ...
Page 19
Fuel system 2-5 governor link mechanism control panel assembly removal • remove: air cleaner (see cleaner body removal) air cleaner mount bracket bolts [a] air cleaner mount bracket [b] control panel mounting bolts [c] • remove the control panel assembly [a] while unhooking the governor spring [b] e...
Page 20
2-6 fuel system governor link mechanism governor arm installation • insert the jig pin (2 mm dia) [i] through the jig pin hole of governor shaft [b]. • install the governor arm [a] onto the governor shaft [b] temporarily. • be sure the link spring [c] around the throttle link rod [d] is inplace and ...
Page 21
Fuel system 2-7 governor link mechanism governor assembly inspection visually check all governor parts for wear and damage. If any parts are worm or damaged, replace them. Governor shaft removal • split the crankcase (see camshaft/crankcase chapter). • unscrew the governor shaft plate screws [a], an...
Page 22
2-8 fuel system carburetor fuel and air flow the main system of the carburetor consists of the main jet [a], valve seat [b] main nozzle [c], and the main air passage [d] (main air jet [e]). The main system meters fuel to the engine during moderate to heavy load conditions. Fuel flows through the mai...
Page 23
Fuel system 2-9 carburetor fuel shut off solenoid valve (electric starter model) to avoid after firing when stopping the engine, a solenoid actuated fuel shut off solenoid valve [a] is installed in the carburetor bowl. The valve shuts off the fuel supply to the valve seat [b] simultaneously when the...
Page 24
2-10 fuel system carburetor high idle speed adjustment note high idle speed adjustment should be made after the idle speed adjustment is performed. Caution do not adjust high idle speed with the air cleaner removed. • start and warm up the engine thoroughly. Always keep your hands clear of the movin...
Page 25
Fuel system 2-11 carburetor high altitude operation at high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installing a smaller diameter main-jet in the carbureto...
Page 26
2-12 fuel system carburetor • remove: air cleaner and related parts (see cleaner body). • turn the fuel shut off valve to the off position. • drain the carburetor. • disconnect the fuel tube at the fuel inlet joint [a] of the carburetor. • remove the carburetor mounting bolts [b] and nuts [c]. • dis...
Page 27
Fuel system 2-13 carburetor carburetor disassembly/assembly • refer to the illustration shown for disassembly and assembly. • there are several passage plugs (ball plugs) in the carburetor body. Do not remove. • before disassembly, mark the outside of choke valve and throttle valves for assembling t...
Page 28
2-14 fuel system carburetor carburetor cleaning clean the carburetor in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low...
Page 29
Fuel system 2-15 carburetor • with the float [a] assembly installed onto the carburetor body [b], hold the carburetor upside down at eye level. Gently support the float with a finger and bring it down slowly so that the float arm tab [c] just touches the float valve needle [d]. The float lower surfa...
Page 30
2-16 fuel system intake manifold intake manifold removal • remove: air cleaner (see cleaner body removal) fan housing carburetor (see carburetor removal) • cut off the band [a] and harness and/or wire lead are released from intake manifold. • remove the manifold mounting bolts [b] and the intake man...
Page 31
Fuel system 2-17 intake manifold intake manifold inspection • inspect the intake manifold for cracks or porous casting. • cracks not visible to the eye may be detected by coating the suspected area with mixture of 25% kerosene and 75% light engine oil. • wipe the area dry and immediately apply a coa...
Page 32
2-18 fuel system fuel pump, fuel filter the fuel pump cannot be disassembled, if any damage for the pump is noticed replace it with a new one. Fuel pump inspection • check the vent hole [a] and filter [b] for plugging or clogging. If vent hole and filter are plugged or clogged, remove the foreign ma...
Page 33
Fuel system 2-19 air cleaner element removal • remove the air cleaner cover nut [a] and the air cleaner cover [b]. • remove: foam element [a] paper element [b] element installation • install the element correctly on the air cleaner body. • be sure the paper element is in-place in the air cleaner bod...
Page 34
2-20 fuel system air cleaner • clean the paper element [a] by tapping it gently on a flat surface to remove dust. If the element is very dirty, replace it with a new one. Caution do not use compressed air to clean the paper element. Do not oil the paper or foam element. Cleaner body removal • remove...
Page 35: Cooling System
Cooling system 3-1 cooling system table of contents 3 exploded view....................................................................................................................................................................3-2 cooling fan ........................................................
Page 36
3-2 cooling system exploded view t1: 2.0 n 1 m (0.2 kg 1 m, 18 in 1 lb) t2: 5.9 n 1 m (0.6 kg 1 m, 52 in 1 lb) t3: 6.9 n 1 m (0.7 kg 1 m, 61 in 1 lb).
Page 37
Cooling system 3-3 cooling fan cooling fan removal • refer to flywheel removal in electrical system chapter. Cooling fan installation • refer to flywheel installation in electrical system chapter. Cooling fan inspection • visually inspect the blades [a] in the cooling fan [b]. If they are any cracks...
Page 39: Engine Top End
Engine top end 4-1 engine top end table of contents 4 exploded view....................................................................................................................................................................4-2 specifications .....................................................
Page 40
4-2 engine top end exploded view o: apply engine oil. T1: 6.9 n 1 m (0.7 kg 1 m, 61 in 1 lb) t2: 9.8 n 1 m (1.0 kg 1 m, 87 in 1 lb) t3: 28 n 1 m (2.8 kg 1 m, 21 ft 1 lb).
Page 41
Engine top end 4-3 exploded view g: apply grease. S: follow the specific tightening sequence. T1: 2.0 n 1 m (0.2 kg 1 m, 18 in 1 lb) t2: 5.9 n 1 m (0.6 kg 1 m, 52 in 1 lb) t3: 6.9 n 1 m (0.7 kg 1 m, 61 in 1 lb) t4: 28 n 1 m (2.8 kg 1 m, 21 ft 1 lb) t5: 22 n 1 m (2.2 kg 1 m, 16 ft 1 lb).
Page 42
4-4 engine top end specifications item service limit cylinder head: cylinder compression (min) [390 kpa (57 psi)] (min) cylinder head warp 0.05 mm (0.002 in.) valves: valve head thickness intake, exhaust 0.35 mm (0.014 in.) valve stem runout intake, exhaust 0.05 mm (0.002 in.) valve stem diameter in...
Page 43
Engine top end 4-5 cylinder head compression measurement • before measuring compression, do the following. Be sure the battery is fully charged. Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running. Stop the...
Page 44
4-6 engine top end cylinder head cylinder head assembly removal • remove: air cleaner (see fuel system chapter) fan housing (see electrical system chpater) muffler (see muffler exhaust pipe removal) carburetor (see fuel system chapter) intake manifold (see fuel system chapter) spark plug • unscrew t...
Page 45
Engine top end 4-7 cylinder head • tighten the cylinder head bolts following the tightening sequence. Torque - cylinder head bolts: 25 n 1 m (2.6 kg 1 m, 19.0 ft 1 lb) caution a torque wrench must be used to assure proper torque. Improper tightening of the head bolts can result in warping of the cyl...
Page 46
4-8 engine top end cylinder head push rod inspection • place the rocker arm push rod in v blocks that are as far apart as possible, and set a dial gauge on the rod at a point halfway between the blocks. Turn the rod to measure the runout. The difference between highest and the lowest dial readings i...
Page 47
Engine top end 4-9 cylinder head • valve installation. Apply engine oil to the valve stem to avoid damaging the stem seal. Check to see that the valve moves smoothly up and down in the guide. Check to see that the valve seats properly in the valve seat. If it does not, repair the valve seat. • rocke...
Page 48
4-10 engine top end valves valve clearance inspection note valve clearance must be checked when the engine is cold (at room temperature). • remove the rocker cover (see cylinder head removal). • place the piston at top dead center (tdc) of the compression stroke turning the crankshaft clockwise faci...
Page 49
Engine top end 4-11 valves valve seat inspection • remove the valve. (see valve mechanism removal/installation) • inspect the valve seats for damage. If the seats are warped or distorted beyond reconditioning, replace the cylinder head. • pitted or worn valve seats can be refaced. Lap the valves to ...
Page 50
4-12 engine top end valves marks stamped on the cutter: the marks stamped on the back of the cutter represent the following. 1 cutter number, selected from 1 to 12 30 cutter angle [a] 37.5 outer diameter of cutter [b] ks8b manufactured lot number operating procedures: • clean the seat area carefully...
Page 51
Engine top end 4-13 valves • coat the face of valve sparingly with a fine lapping compound. • use the vacuum cup tool [a], to grip top of the valve [b]. Rotate the valve in a circular motion to lap the valve to the seat. • lift the valve slightly from the seat every 8 to 10 strokes, continue lapping...
Page 52
4-14 engine top end valves valve stem runout • support the valve in v blocks at each end of the stem. • position a dial gauge perpendicular to the stem. • turn the valve and read the variation on the dial gauge. If the stem runout is greater than service limit, replace the valve. Valve stem runout s...
Page 53
Engine top end 4-15 cylinder, piston piston removal • split the crankcase (see camshaft/crankshaft chapter). • remove the camshaft (see camshaft/crankshaft chapter). • turn the crankshaft to expose the connecting rod cap bolts [a]. • remove the bolts and take off the connecting rod caps [b]. Note no...
Page 54
4-16 engine top end cylinder, piston piston installation • install the expander [a] in the piston oil ring groove so that the expander ends [b] touch together, never overlap. • install the upper and lower steel rails. There is no up or down to the rails. They can be installed either way. • do not mi...
Page 55
Engine top end 4-17 cylinder, piston • apply engine oil to the piston skirt and the cylinder bore. Using the piston ring compressor grip [a] and the belt [b], lightly tap the top of the piston with a plastic mallet [c] to insert the piston and connecting rod into the cylinder. Special tool - piston ...
Page 56
4-18 engine top end cylinder, piston piston cleaning • remove the piston and piston rings (see piston removal). Caution never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings. • scrape the carbon off [a] t...
Page 57
Engine top end 4-19 cylinder, piston piston ring end gap • remove the piston rings. • push each ring (one at a time) in the cylinder bore to a point close to the bottom of the cylinder bore. Use the piston to push it in to be sure it is square. • measure the gap [a] between the ends of the ring [b] ...
Page 58
4-20 engine top end cylinder, piston piston diameter • measure the outside diameter of the piston 12.5 mm (0.9 in.) up from the bottom of the piston at a right angle to the direction of the piston pin hole. If the measurement is less than the service limit, replace the piston. Piston diameter servic...
Page 59
Engine top end 4-21 cylinder, piston change to a honing stone for finishing, the final bore diameter should be as shown in the table. Be sure the correct stone is used and the stone is not worn. • clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and hea...
Page 60
4-22 engine top end muffler muffler removal • remove the bolt [b] on the muffler bracket. • unscrew the flange nuts [a], and remove the muffler. Use a penetrating oil if necessary to break threads loose. • do not use unnecessary force when removing the muffler assembly, or they could become damaged ...
Page 61: Lubrication System
Lubrication system 5-1 lubrication system table of contents 5 exploded view....................................................................................................................................................................5-2 engine oil flow chart.......................................
Page 62
5-2 lubrication system exploded view o: apply engine oil. G: apply grease. S: follow the specific tighening sequence. Ss: apply silicone sealant. T1: 2.0 n 1 m (0.2 kg 1 m, 18 in 1 lb) t2: 5.9 n 1 m (0.6 kg 1 m, 52 in 1 lb) t3: 6.9 n 1 m (0.7 kg 1 m, 61 in 1 lb) t4: see page 5–6. T5: 25 n 1 m (2.6 k...
Page 63
Lubrication system 5-3 engine oil flow chart.
Page 64
5-4 lubrication system specifications item standard engine oil: grade api service classification: sf, sg, sh, or sj class viscosity sae40, sae30, sae10w-30 / sae10w-40, or sae5w-20 capacity 1.4 l (1.5 us qt) [when oil filter is not removed] 1.6 l (1.7 us qt) [when oil filter is removed] level betwee...
Page 65
Lubrication system 5-5 engine oil and oil filter caution engine operation with insufficient, deteriorated, or contami- nated engine oil will cause accelerated wear and may result in engine seizure and accident. Before starting the engine for the first time, add oil: the engine is shipped dry. Preoil...
Page 66
5-6 lubrication system engine oil and oil filter • remove the oil filler cap and pour in the specified type and amount of oil. Engine oil : grade: api service classification: sf, sg, sh or sj class viscosity: sae40, sae30, sae10w-30/sae10w-40, or sae5w-20 capacity: 1.4 l (1.5 us 1 qt) [when oil filt...
Page 67
Lubrication system 5-7 pressurized lubrication system the engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase. The oil is pumped to a replaceable oil filter cartridge, through the engine’s oil pas...
Page 68
5-8 lubrication system oil pump, relief valve oil pump, relief valve removal • remove the crankcase cover (see camshaft/crankshaft chapter). • unscrew the mounting bolts and remove the oil pump parts assembly (pump gear, pump cover plate, pump shaft, pins and rotors). • take off the relief valve spr...
Page 69
Lubrication system 5-9 oil pump, relief valve • measure the inside diameter [a] of the pump housing with a inside micrometer at several points. If the inside diameter is more than the service limit, replace the crankcase cover. Pump housing inside diameter service limit: 40.801 mm(1.6063 in.) • meas...
Page 70
5-10 lubrication system oil pump, relief valve if cleaning does not solve the problem, replace the relief valve parts. If necessary, put the ball in position and lightly tap the ball with a suitable tools to form a perfect seat. • measure free length [a] of the spring with a vernier caliper. If the ...
Page 71
Lubrication system 5-11 oil screen oil screen removal • remove the crankcase cover (see camshaft/crankcase chapter). • unscrew the mounting bolts [a] and remove the spacers [b] and pipe [c]. • push [d] the oil screen with thumbs and remove it. Oil screen installation • clean the oil screen thoroughl...
Page 73: Camshaft/crankshaft
Camshaft/crankshaft 6-1 camshaft/crankshaft table of contents 6 exploded view....................................................................................................................................................................6-2 specifications ...........................................
Page 74
6-2 camshaft/crankshaft exploded view o: apply engine oil. G: apply grease. S: follow the specific tightening sequence. Ss: apply silicone sealant. T1: 2.0 n 1 m (0.2 kg 1 m, 18 in 1 lb) t2: 5.9 n 1 m (0.6 kg 1 m, 52 in 1 lb) t3: 9.8 n 1 m (1.0 kg 1 m, 87 in 1 lb) t4: 25 n 1 m (2.6 kg 1 m, 19 ft 1 l...
Page 75
Camshaft/crankshaft 6-3 specifications item service limit camshaft, tappet: cam lobe height intake 29.621 mm (1.166 in.) exhaust 29.621 mm (1.166 in.) camshaft journal diameter pto side 15.985 mm (0.6293 in.) flywheel side 15.985 mm (0.6293 in.) camshaft bearing inside diameter crankcase 16.136 mm (...
Page 76
6-4 camshaft/crankshaft crankcase crankcase cover removal • set the engine on a clean surface while parts are being removed. • drain the oil (see lubrication system chapter). • remove: exhaust pipe and muffler (see engine top end chapter) control panel (see fuel system chapter) governor arm (see fue...
Page 77
Camshaft/crankshaft 6-5 crankcase • check to see that the crankcase dowel pins [a] are in place on the crankcase. • install the gasket [b] on the crankcase. • install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown. Torque - crankcase cover bolts: 25...
Page 78
6-6 camshaft/crankshaft crankcase cleaning • remove: camshaft and tappets (see camshaft, tappet removal) crankshaft (see crankshaft removal) • clean up the crankcase and cover with a high flash-point solvent, and blow out any foreign particles that may be in the pockets inside of the crankcase with ...
Page 79
Camshaft/crankshaft 6-7 breather the function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by ...
Page 80
6-8 camshaft/crankshaft breather breather valve removal • remove the bolts [a] and breather chamber cover [b]. • remove the pipe [a]. • remove the breather valve [b] unscrewing the mounting screws [a] at the cam gear side of the crankcase (see camshaft, tappet removal). Breather valve inspection • v...
Page 81
Camshaft/crankshaft 6-9 breather breather valve installation • be sure the drain hole [a] on the breather chamber does not accumulate with slugs. • install the breather valve on the cam gear side of the crankcase (see camshaft, tappet removal). Torque - breather valve screws: 2.0 n 1 m (0.2 kg 1 m, ...
Page 82
6-10 camshaft/crankshaft camshaft, tappet camshaft, tappet removal • set the engine on a clean surface while parts are being removed. • drain the oil (see lubrication system chapter). • remove: muffler (see engine top end chapter) throttle control panel (see fuel system chapter) carburetor (see fuel...
Page 83
Camshaft/crankshaft 6-11 camshaft, tappet camshaft disassembly • remove the governor assembly (see fuel system chapter). • remove: spring [a] do not remove the acr (automatic compression release) weight [b]. Camshaft assembly • install the governor assembly (see fuel system chapter). • after assembl...
Page 84
6-12 camshaft/crankshaft camshaft, tappet • measure both camshaft journals at several points around the journal circumference. If the journal diameter is less than the service limit, replace the camshaft. Pto side camshaft journal diameter service limit: 15.985 mm (0.6293 in.) flywheel side camshaft...
Page 85
Camshaft/crankshaft 6-13 crankshaft, connecting rod connecting rod removal • remove: piston (see engine top end chapter) connecting rod installation • install: piston (see engine top end chapter) crankshaft removal • set the engine on a clean surface while parts are being removed. • drain the oil (s...
Page 86
6-14 camshaft/crankshaft crankshaft, connecting rod • measure connection rod twist. With the big-end arbor still on the v blocks, hold the connection rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor t...
Page 87
Camshaft/crankshaft 6-15 crankshaft, connecting rod crankshaft runout • measure the crankshaft runout. Set the crankshaft in a flywheel alignment jig or on v blocks gauge. Set a dial gauge against both bearing journals. Turn the crankshaft slowly to measure the runout. The difference between the hig...
Page 89: Electrical System
Electrical system 7-1 electrical system table of contents 7 exploded view....................................................................................................................................................................7-2 specifications ...............................................
Page 90
7-2 electrical system exploded view g: apply grease. Ss: apply silicone sealant. T1: 3.4 n 1 m (0.35 kg 1 m, 30 in 1 lb) t2: 5.9 n 1 m (0.6 kg 1 m, 52 in 1 lb) t3: 9.8 n 1 m (1.0 kg 1 m, 87 in 1 lb) t4: 15 n 1 m (1.5 kg 1 m, 11 ft 1 lb) t5: 19 n 1 m (1.9 kg 1 m, 14 ft 1 lb) t6: 22 n 1 m (2.2 kg 1 m,...
Page 91
Electrical system 7-3 specifications item standard service limit charging system: regulated output voltage 14.1 v dc 15 v dc alternator stator coil resistance in the text – – – unregulated stator output 28.4 v ac/3000 rpm 26v ac/3000 rpm regulator resistance in the text ignition system: ignition coi...
Page 92
7-4 electrical system wiring diagram.
Page 93
Electrical system 7-5 precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. Always check battery condition be...
Page 94
7-6 electrical system charging, ignition system flywheel, stator coil removal • remove: screws [b] and screen [a] • loosen the fan housing bolts [a] and remove the fan housing [b]. • remove: bolts [a] ignition coils [b] (see ignition coil removal) • hold the flywheel with a suitable tool [c], remove...
Page 95
Electrical system 7-7 charging, ignition system • using a suitable flywheel puller [a], remove the flywheel [b]. Caution always use flywheel puller. • remove: woodruff key [a] screws [b] stator coil [c] flywheel, stator coil installation • install the stator coil and tighten the screws. Torque - sta...
Page 96
7-8 electrical system charging, ignition system • fit the conical washer [a] onto the flywheel bolt [b], and tighten the flywheel bolt. Caution make sure the direction of conical washer [a] for flywheel bolt [b]. Direction is as illustration. Torque - flywheel bolt: 56 n 1 m (5.7 kg 1 m, 41 ft 1 lb)...
Page 97
Electrical system 7-9 charging, ignition system charging system operational inspection • check battery condition. Note always check battery condition before condemning other parts of the charging system. The battery must be fully charged in order to conduct accurate charging system tests. • warm up ...
Page 98
7-10 electrical system charging, ignition system regulator removal • remove: stator coil lead connector [a] regulator screw [b] regulator [c] regulator installation • install the regulator and tighten the screws. Torque - regulator screw: 3.4 n 1 m (0.35 kg 1 m, 30 in 1 lb) regulator resistance • se...
Page 99
Electrical system 7-11 charging, ignition system (with charging monitor type … 5 blades) if the resistance is not as specified replace the regulator..
Page 100
7-12 electrical system charging, ignition system this engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the spark plugs. The system consists of the following: inductive ignition assemblies permanent magnet flywheel spark plugs stop switc...
Page 101
Electrical system 7-13 charging, ignition system ignition coil removal • remove: fan housing (see flywheel, stator coil removal) spark plug cap [a] stop switch lead connector [b] bolts [c] ignition coil [d] ignition coil installation • install ignition coil on crankcase so that the stop switch lead ...
Page 102
7-14 electrical system charging, ignition system ignition coil inspection • remove the ignition coils (see ignition coil removal). • measure the primary winding resistance as follows: set the hand tester to the r 2 1 k range. Special tool - hand tester: 57001–1394 make the measurements shown in the ...
Page 103
Electrical system 7-15 starter system starter motor removal • remove the mounting bolts [a] and pull the starter motor [b] from the engine. Starter motor installation • clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts. Torque - star...
Page 104
7-16 electrical system starter system starter motor assembly • assembly is the reverse of disassembly. • apply a small amount of grease [a] to the armature shaft. • do not reuse the snap ring [b]. Replace it with a new one. • check the cap and replace it with a new one if damaged. • fit the projecti...
Page 105
Electrical system 7-17 starter system • measure the depth of the grooves between the commutator segments. If the grooves are shallower than the specified limit, replace the armature with a new one. If the grooves are only dirty, clean them carefully. Commutator groove depth limit less than 0.9 mm (0...
Page 106
7-18 electrical system starter system • test the armature winding for shorts. Place the armature on a growler [a]. Hold a thin metal strip (e.G., hack saw blade) on top of the armature. Turn on the growler and rotate the armature one complete turn. If the metal strip vibrates, the windings are inter...
Page 107: Troubleshooting
Troubleshooting 8-1 troubleshooting table of contents 8 engine troubleshooting guide ...........................................................................................................................................8-2 starter motor troubleshooting guide........................................
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8-2 troubleshooting engine troubleshooting guide if the engine malfunctions, check if the way the engine is used is correct. If engine malfunctions even if engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubleshooting pro...
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Troubleshooting 8-3 engine troubleshooting guide.
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8-4 troubleshooting engine troubleshooting guide.
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Troubleshooting 8-5 engine troubleshooting guide.
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8-6 troubleshooting starter motor troubleshooting guide 1. Disconnect spark plug caps from the spark plugs. 2. Turn engine switch to “start” position and check condition. Engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test. Caution if starter does ...